TRAINING 333999
REGULATIONS
FOUNDRY MELTING/CASTING NC II
AUTOMOTIVE MANUFACTURING SECTOR
TECHNICAL EDUCATION AND SKILLS DEVELOPMENT AUTHORITY
East Service Road, South Superhighway, Taguig City, Metro Manila
TABLE OF CONTENTS
AUTOMOTIVE/LAND TRANSPORT SECTOR
FOUNDRY MELTING/CASTING NC II
Page No.
SECTION 1 FOUNDRY MELTING/CASTING NC II 1-2
QUALIFICATION
SECTION 2 COMPETENCY STANDARDS
Basic Competencies 3-15
Common Competencies 16-27
Core Competencies 28-49
- FOUNDRY MELTING/CASTING NC II
SECTION 3 TRAINING STANDARDS
3.1 Curriculum Design 50-53
3.2 Training Delivery 54
3.3 Trainee Entry Requirements 55
3.4 List of Tools, Equipment and Materials 55-57
3.5 Training Facilities 57
3.6 Trainers' Qualifications 57
3.7 Institutional Assessment 57
SECTION 4 NATIONAL ASSESSMENT AND 58
CERTIFICATION ARRANGEMENTS
ANNEX A: COMPETENCY MAP 59
DEFINITION OF TERMS 60-62
ACKNOWLEDGEMENTS 63
TRAINING REGULATIONS FOR
FOUNDRY MELTING/CASTING NC II
SECTION 1 FOUNDRY MELTING/ CASTING NC II QUALIFICATION
The FOUNDRY MELTING/CASTING NC II Qualification consists of competencies that a
person must achieve to be able to melt different kinds of metals, cast it and clean. This will not
be limited to ferrous metals and only one type of furnace.
Melting of different type of metals may use different kinds of furnaces. The melting operations
may use different furnaces, each type of which may use different heating systems and fuel.
When the metal is molten, the composition is checked and adjusted. Then this is tapped from
the furnace and cast into molds. The resulting castings are fettled and cleaned.
The furnaces are subjected to intense heat and temperature. Furnaces are lined with
refractory linings which are eroded in every melting. The refractory linings will need periodic
maintenance and replacement. This unit covers all operations of melting and casting including
the maintenance of furnaces.
Tasks undertaken include utilizing knowledge in estimating metal charges, controlling
temperature and chemical composition and designated procedures, use of correct and
appropriate tools and equipment in cleaning castings and maintaining furnaces.
He should also be able to inspect, measure and interpret drawings and repair procedures;
sets up and operates variety of specialized furnaces and uses precision measuring instrument
in operating and maintaining the melting equipment.
This Qualification is packaged from the competency map of the Automotive Industry
(Manufacturing sub-sector) as shown in Annex A.
The Units of Competency comprising this Qualification include the following:
CODE NO. BASIC COMPETENCIES
500311105 Participate in Workplace Communication
500311106 Work in Team Environment
500311107 Practice Career Professionalism
500311108 Practice Occupational Health and Safety Procedures
CODE NO. COMMON COMPETENCIES
ALT742201 Read & Interpret Engineering Drawings
ALT311202 Perform Mensuration and Calculation
ALT723203 Read, Interpret and Apply Specifications and Manuals
ALT723205 Perform Shop Maintenance
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CODE NO. CORE COMPETENCIES
ALT812307 Operate Melting Furnaces (Non Electric)
ALT812308 Operate Cupola Melting Furnaces
ALT812309 Operate Electric Induction Melting Furnaces
ALT812310 Fettle and Trim Metal Castings/Forgings
ALT812311 Perform Refractory Installation and Repair
ALT821303 Use and Maintain Measuring Instrument
A person who has achieved this Qualification is competent to be:
Foundry Melter
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SECTION 2 COMPETENCY STANDARDS
This section gives the details of the contents of the basic, common and core units of
competency required in FOUNDRY MELTING/CASTING NC II.
BASIC COMPETENCIES
UNIT OF COMPETENCY : PARTICIPATE IN WORKPLACE COMMUNICATION
UNIT CODE : 500311105
UNIT DESCRIPTOR : This unit covers the knowledge, skills and attitudes required to
gather, interpret and convey information in response to
workplace requirements.
ELEMENT PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1. Obtain and 1.1 Specific and relevant information is accessed from
convey appropriate sources
workplace 1.2 Effective questioning , active listening and speaking skills are
information used to gather and convey information
1.3 Appropriate medium is used to transfer information and ideas
1.4 Appropriate non- verbal communication is used
1.5 Appropriate lines of communication with supervisors and
colleagues are identified and followed
1.6 Defined workplace procedures for the location and storage of
information are used
1.7 Personal interaction is carried out clearly and concisely
2. Participate in 2.1 Team meetings are attended on time
workplace 2.2 Own opinions are clearly expressed and those of others are
meetings and listened to without interruption
discussions 2.3 Meeting inputs are consistent with the meeting purpose and
established protocols
2.4 Workplace interactions are conducted in a courteous manner
2.5 Questions about simple routine workplace procedures and
maters concerning working conditions of employment are
asked and responded to
2.6 Meetings outcomes are interpreted and implemented
3. Complete 3.1 Range of forms relating to conditions of employment are
relevant work completed accurately and legibly
related 3.2 Workplace data is recorded on standard workplace forms and
documents documents
3.3 Basic mathematical processes are used for routine
calculations
3.4 Errors in recording information on forms/ documents are
identified and properly acted upon
3.5 Reporting requirements to supervisor are completed according
to organizational guidelines
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RANGE OF VARIABLES
VARIABLE RANGE
1. Appropriate sources 1.1. Team members
1.2. Suppliers
1.3. Trade personnel
1.4. Local government
1.5. Industry bodies
2. Medium 2.1. Memorandum
2.2. Circular
2.3. Notice
2.4. Information discussion
2.5. Follow-up or verbal instructions
2.6. Face to face communication
3. Storage 3.1. Manual filing system
3.2. Computer-based filing system
4. Forms 4.1. Personnel forms, telephone message forms, safety
reports
5. Workplace interactions 5.1. Face to face
5.2. Telephone
5.3. Electronic and two way radio
5.4. Written including electronic, memos, instruction and
forms, non-verbal including gestures, signals, signs
and diagrams
6. Protocols 6.1. Observing meeting
6.2. Compliance with meeting decisions
6.3. Obeying meeting instructions
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EVIDENCE GUIDE
1. Critical aspects of Assessment requires evidence that the candidate:
competency 1.1. Prepared written communication following standard
format of the organization
1.2. Accessed information using communication equipment
1.3. Made use of relevant terms as an aid to transfer
information effectively
1.4. Conveyed information effectively adopting the formal or
informal communication
2. Underpinning 2.1. Effective communication
knowledge and 2.2. Different modes of communication
attitudes 2.3. Written communication
2.4. Organizational policies
2.5. Communication procedures and systems
2.6. Technology relevant to the enterprise and the
individual’s work responsibilities
3. Underpinning skills 3.1. Follow simple spoken language
3.2. Perform routine workplace duties following simple
written notices
3.3. Participate in workplace meetings and discussions
3.4. Complete work related documents
3.5. Estimate, calculate and record routine workplace
measures
3.6. Basic mathematical processes of addition, subtraction,
division and multiplication
3.7. Ability to relate to people of social range in the
workplace
3.8. Gather and provide information in response to
workplace Requirements
4. Resource 4.1. Fax machine
implications 4.2. Telephone
4.3. Writing materials
4.4. Internet
5. Method of 5.1. Direct Observation
assessment 5.2. Oral interview and written test
6. Context of 6.1. Competency may be assessed individually in the actual
assessment workplace or through accredited institution
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UNIT OF COMPETENCY: WORK IN TEAM ENVIRONMENT
UNIT CODE : 500311106
UNIT DESCRIPTOR : This unit covers the skills, knowledge and attitudes to identify
role and responsibility as a member of a team.
ELEMENT PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1. Describe team role 1.1. The role and objective of the team is identified from
and scope available sources of information
1.2. Team parameters, reporting relationships and
responsibilities are identified from team discussions and
appropriate external sources
2. Identify own role 2.1. Individual role and responsibilities within the team
and responsibility environment are identified
within team 2.2. Roles and responsibility of other team members are
identified and recognized
2.3. Reporting relationships within team and external to team
are identified
3. Work as a team 3.1. Effective and appropriate forms of communications used
member and interactions undertaken with team members who
contribute to known team activities and objectives
3.2. Effective and appropriate contributions made to
complement team activities and objectives, based on
individual skills and competencies and workplace context
3.3. Observed protocols in reporting using standard operating
procedures
3.4. Contribute to the development of team work plans based
on an understanding of team’s role and objectives and
individual competencies of the members.
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RANGE OF VARIABLES
VARIABLE RANGE
1. Role and objective 1.1. Work activities in a team environment with enterprise or
of team specific sector
1.2. Limited discretion, initiative and judgement maybe
demonstrated on the job, either individually or in a team
environment
2. Sources of 2.1. Standard operating and/or other workplace procedures
information 2.2. Job procedures
2.3. Machine/equipment manufacturer’s specifications and
instructions
2.4. Organizational or external personnel
2.5. Client/supplier instructions
2.6. Quality standards
2.7. OHS and environmental standards
3. Workplace context 3.1. Work procedures and practices
3.2. Conditions of work environments
3.3. Legislation and industrial agreements
3.4. Standard work practice including the storage, safe
handling and disposal of chemicals
3.5. Safety, environmental, housekeeping and quality
guidelines
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EVIDENCE GUIDE
1. Critical aspects of Assessment requires evidence that the candidate:
competency 1.1. Operated in a team to complete workplace activity
1.2. Worked effectively with others
1.3. Conveyed information in written or oral form
1.4. Selected and used appropriate workplace language
1.5. Followed designated work plan for the job
1.6. Reported outcomes
2. Underpinning 2.1. Communication process
knowledge and 2.2. Team structure
attitude
2.3. Team roles
2.4. Group planning and decision making
3. Underpinning skills 3.1. Communicate appropriately, consistent with the culture of
the workplace
4. Resource The following resources MUST be provided:
implications 4.1. Access to relevant workplace or appropriately simulated
environment where assessment can take place
4.2. Materials relevant to the proposed activity or tasks
5. Method of Competency may be assessed through:
assessment 5.1. Observation of the individual member in relation to the
work activities of the group
5.2. Observation of simulation and or role play involving the
participation of individual member to the attainment of
organizational goal
5.3. Case studies and scenarios as a basis for discussion of
issues and strategies in teamwork
6. Context of 6.1. Competency may be assessed in workplace or in a
assessment simulated workplace setting
6.2. Assessment shall be observed while task are being
undertaken whether individually or in group
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UNIT OF COMPETENCY: PRACTICE CAREER PROFESSIONALISM
UNIT CODE : 500311107
UNIT DESCRIPTOR : This unit covers the knowledge, skills and attitudes in promoting
career growth and advancement.
PERFORMANCE CRITERIA
ELEMENT Italicized terms are elaborated in the Range of Variables
1. Integrate personal 1.1 Personal growth and work plans are pursued towards
objectives with improving the qualifications set for the profession
organizational goals 1.2 Intra- and interpersonal relationships is are maintained in the
course of managing oneself based on performance
evaluation
1.3 Commitment to the organization and its goal is demonstrated
in the performance of duties
2. Set and meet work 2.1 Competing demands are prioritized to achieve personal,
priorities team and organizational goals and objectives.
2.2 Resources are utilized efficiently and effectively to manage
work priorities and commitments
2.3 Practices along economic use and maintenance of
equipment and facilities are followed as per established
procedures
3. Maintain 3.1 Trainings and career opportunities are identified and
professional growth availed of based on job requirements
and development 3.2 Recognitions are sought/received and demonstrated as
proof of career advancement
3.3 Licenses and/or certifications relevant to job and career
are obtained and renewed
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RANGE OF VARIABLES
VARIABLE RANGE
1. Evaluation 1.1 Performance Appraisal
1.2 Psychological Profile
1.3 Aptitude Tests
2. Resources 2.1 Human
2.2 Financial
2.3 Technology
2.3.1 Hardware
2.3.2 Software
3. Trainings and career 3.1 Participation in training programs
opportunities 3.1.1 Technical
3.1.2 Supervisory
3.1.3 Managerial
3.1.4 Continuing Education
3.2 Serving as Resource Persons in conferences and
workshops
4. Recognitions 4.1 Recommendations
4.2 Citations
4.3 Certificate of Appreciations
4.4 Commendations
4.5 Awards
4.6 Tangible and Intangible Rewards
5. Licenses and/or 5.1 National Certificates
certifications 5.2 Certificate of Competency
5.3 Support Level Licenses
5.4 Professional Licenses
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EVIDENCE GUIDE
1. Critical aspects of Assessment requires evidence that the candidate:
competency 1.1 Attained job targets within key result areas (KRAs)
1.2 Maintained intra - and interpersonal relationship in the
course of managing oneself based on performance
evaluation
1.3 Completed trainings and career opportunities which are
based on the requirements of the industries
1.4 Acquired and maintained licenses and/or certifications
according to the requirement of the qualification
2. Underpinning 2.1 Work values and ethics (Code of Conduct, Code of Ethics,
knowledge etc.)
2.2 Company policies
2.3 Company operations, procedures and standards
2.4 Fundamental rights at work including gender sensitivity
2.5 Personal hygiene practices
3. Underpinning skills 3.1 Appropriate practice of personal hygiene
3.2 Intra and Interpersonal skills
3.3 Communication skills
4. Resource The following resources MUST be provided:
implications 4.1 Workplace or assessment location
4.2 Case studies/scenarios
5. Method of Competency may be assessed through:
assessment 5.1 Portfolio Assessment
5.2 Interview
5.3 Simulation/Role-plays
5.4 Observation
5.5 Third Party Reports
5.6 Exams and Tests
6. Context of 6.1 Competency may be assessed in the work place or in a
assessment simulated work place setting
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UNIT OF COMPETENCY : PRACTICE OCCUPATIONAL HEALTH AND SAFETY
PROCEDURES
UNIT CODE : 500311108
UNIT DESCRIPTOR : This unit covers the outcomes required to comply with
regulatory and organizational requirements for
occupational health and safety.
ELEMENT PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1. Identify hazards and 1.1 Safety regulations and workplace safety and hazard
risks control practices and procedures are clarified and
explained based on organization procedures
1.2 Hazards/risks in the workplace and their corresponding
indicators are identified to minimize or eliminate risk to co-
workers, workplace and environment in accordance with
organization procedures
1.3 Contingency measures during workplace accidents, fire
and other emergencies are recognized and established in
accordance with organization procedures
2. Evaluate hazards and 2.1 Terms of maximum tolerable limits which when exceeded
risks will result in harm or damage are identified based on
threshold limit values (TLV)
2.2 Effects of the hazards are determined
2.3 OHS issues and/or concerns and identified safety hazards
are reported to designated personnel in accordance with
workplace requirements and relevant workplace OHS
legislation
3. Control hazards and 3.1 Occupational Health and Safety (OHS) procedures for
risks controlling hazards/risks in workplace are consistently
followed
3.2 Procedures for dealing with workplace accidents, fire and
emergencies are followed in accordance with organization
OHS policies
3.3 Personal protective equipment (PPE) is correctly used in
accordance with organization OHS procedures and
practices
3.4 Appropriate assistance is provided in the event of a
workplace emergency in accordance with established
organization protocol
4.1 Emergency-related drills and trainings are participated
4. Maintain OHS in as per established organization guidelines and
awareness procedures
4.2 OHS personal records are completed and updated in
accordance with workplace requirements
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RANGE OF VARIABLES
VARIABLE RANGE
1. Safety regulations May include but are not limited to:
1.1 Clean Air Act
1.2 Building code
1.3 National Electrical and Fire Safety Codes
1.4 Waste management statutes and rules
1.5 Philippine Occupational Safety and Health Standards
1.6 DOLE regulations on safety legal requirements
1.7 ECC regulations
2. Hazards/Risks May include but are not limited to:
2.1 Physical hazards – impact, illumination, pressure, noise,
vibration, temperature, radiation
2.2 Biological hazards- bacteria, viruses, plants, parasites, mites,
molds, fungi, insects
2.3 Chemical hazards – dusts, fibers, mists, fumes, smoke,
gasses, vapors
2.4 Ergonomics
Psychological factors – over exertion/ excessive force,
awkward/static positions, fatigue, direct pressure, varying
metabolic cycles
Physiological factors – monotony, personal relationship,
work out cycle
3. Contingency May include but are not limited to:
measures 3.1 Evacuation
3.2 Isolation
3.3 Decontamination
3.4 (Calling designed) emergency personnel
4. PPE May include but are not limited to:
4.1 Mask
4.2 Gloves
4.3 Goggles
4.4 Hair Net/cap/bonnet
4.5 Face mask/shield
4.6 Ear muffs
4.7 Apron/Gown/coverall/jump suit
4.8 Anti-static suits
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5.1 Fire drill
5. Emergency-related 5.2 Earthquake drill
drills and training 5.3 Basic life support/CPR
5.4 First aid
5.5 Spillage control
5.6 Decontamination of chemical and toxic
5.7 Disaster preparedness/management
6.1 Medical/Health records
6. OHS personal 6.2 Incident reports
records 6.3 Accident reports
6.4 OHS-related training completed
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
EVIDENCE GUIDE
1. Critical aspects of Assessment requires evidence that the candidate:
competency 1.1 Explained clearly established workplace safety and hazard
control practices and procedures
1.2 Identified hazards/risks in the workplace and its corresponding
indicators in accordance with company procedures
1.3 Recognized contingency measures during workplace
accidents, fire and other emergencies
1.4 Identified terms of maximum tolerable limits based on
threshold limit value- TLV.
1.5 Followed Occupational Health and Safety (OHS) procedures
for controlling hazards/risks in workplace
1.6 Used Personal Protective Equipment (PPE) in accordance
with company OHS procedures and practices
1.7 Completed and updated OHS personal records in accordance
with workplace requirements
2. Underpinning 2.1 OHS procedures and practices and regulations
knowledge and 2.2 PPE types and uses
attitudes 2.3 Personal hygiene practices
2.4 Hazards/risks identification and control
2.5 Threshold Limit Value -TLV
2.6 OHS indicators
2.7 Organization safety and health protocol
2.8 Safety consciousness
2.9 Health consciousness
3. Underpinning 3.1 Practice of personal hygiene
skills 3.2 Hazards/risks identification and control skills
3.3 Interpersonal skills
3.4 Communication skills
4. Resource The following resources must be provided:
implications 4.1 Workplace or assessment location
4.2 OHS personal records
4.3 PPE
4.4 Health records
5. Method of Competency must be assessed through:
assessment 5.1 Portfolio Assessment
5.2 Interview
5.3 Case Study/Situation
6. Context of 6.1 Competency may be assessed in the work place or in a
assessment simulated work place setting
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
COMMON COMPETENCIES
AUTOMOTIVE MANUFACTURING
UNIT TITLE: READ, INTERPRET AND APPLY ENGINEERING DRAWINGS.
UNIT CODE: ALT742201
UNIT DESCRIPTOR: This unit deals with identifying, interpreting and applying specification
from Engineering blue prints or drawings that provides the
measurements of the product and pattern that is to be produced.
ELEMENT PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1. Identify and 1.1 Appropriate Engineering drawings are identified and accessed
access as per job requirements.
engineering 1.2 Version and date of drawing is checked to ensure correct
drawings/ specification and procedure are identified.
specification
2. Interpret drawings 2.1 Relevant dimensions and sections of the drawings/
specifications are located in relation to the work to be conducted
2.2 Information in the manual are interpreted in accordance to
industry practices
3 Apply information 3.1 Engineering drawing is interpreted according to job requirements
in the drawings & 3.2 Work steps are correctly identified in accordance with the
specifications specifications in the drawings.
3.3 Dimensional data and shape are applied according to the given
task
4. Store drawings 4.1 The drawings and specification are stored properly to
ensure prevention of damage, ready access and
updating of information when required in accordance
with company requirements
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RANGE OF VARIABLES
VARIABLE RANGE
1. Engineering drawings Kinds of drawings:
1.1 Casting drawing
1.2 Machining drawing
1.3 Project plan
1.4 Technical drawing
2. Data Data includes but not limited to
2.1 Material specifications
2.2 Process specifications
2.3 Special instructions
2.4 Machining locating points
2.5 Clamping points
2.6 Amount of draft
2.7 Surface finish
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
EVIDENCE GUIDE
1.Critical aspects of Assessment requires evidence that the candidate:
competency 1.1 Identified and accessed drawings/specification
1.2 Interpreted drawings
1.3 Applied information in drawings
1.4 Stored drawings
2. Underpinning 2.1 Types of drawings used in automotive manufacturing industry
knowledge and 2.2 Identification of symbols used in the drawings
attitudes 2.3 Identification of units of measurements
2.4 Unit conversion
2.5 Attention to details, Perseverance, Honesty
3. Underpinning 3.1 Reading and comprehension skills required to identify and
skills interpret engineering drawings and specifications
3.2 Accessing information and data
The following resources MUST be provided:
4. Resource 4.1 All drawings/engineering specifications relative to automotive
implications manufacturing
4.2 Job order, requisitions
4.3 Product sample
Competency MUST be assessed through:
5 Method of 5.1 Observation with questioning
assessment 5.2 Interview
6 Context of 6.1 Assessment must be undertaken in accordance with
assessment the endorsed TESDA assessment guidelines
6.2 Assessment may be conducted in the workplace or a
simulated environment.
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
UNIT OF COMPETENCY: PERFORM MENSURATION AND CALCULATION
UNIT CODE: ALT311202
UNIT DESCRIPTOR: This unit includes identifying, caring for, handling, using and
maintaining measuring instruments.
ELEMENT PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1. Select measuring 1.1 Object or component to be measured is identified
instruments 1.2 Correct specifications are obtained from relevant source
1.3 Appropriate measuring instrument is selected according to
job requirements
2. Carry out 2.1 Measuring tools are selected in line with job requirements
measurements 2.2 Accurate measurements are obtained to job
and calculation 2.3 Calculation needed to complete work tasks are performed
using the four basic process of addition (+), subtraction (-),
multiplication (x) and division (/).
2.4 Calculations involving fractions, percentages and mixed
numbers are used to complete workplace tasks.
2.5 Numerical computation is self-checked and corrected for
accuracy
2.6 Instruments are read to the limit of accuracy of the tool.
3. Maintain 3.1 Measuring instruments are kept free from corrosion
measuring 3.2 Measuring instruments are not dropped to avoid damage
instruments 3.3 Measuring instruments are cleaned before and after using.
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RANGE OF VARIABLES
VARIABLE RANGE
1. Measuring Measuring instruments includes:
instruments 1.1 Multitester 1.7 Try square
1.2 Micrometer (In-out, depth) 1.8 Protractor
1.3 Vernier caliper (Out, 1.9 Height gauge
inside) 1.10 Steel rule
1.4 Dial Gauge with Mag. Std. Shrink rule
1.5 Straight Edge
1.6 Thickness gauge
Kinds of part mensuration include:
2. Calculation 2.1 Volume
2.2 Area
2.3 Displacement
2.4 Inside diameter
2.5 Circumference
2.6 Length
2.7 Thickness
2.8 Outside diameter
2.9 Taper
2. 10 Out of roundness
2.11 Shrinkage allowance
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
EVIDENCE GUIDE
Assessment requires evidence that the candidate:
1. Critical aspects 1.1 Selected measuring instruments
of competency 1.2 Carried-out measurements and calculations.
1.3 Maintained measuring instruments
2.1 Types of Measuring instruments and its uses
2. Underpinning 2.2 Safe handling procedures in using measuring instruments
knowledge and 2.3 Four fundamental operation of mathematics
attitudes 2.4 Formula for Volume, Area, Perimeter and other geometric
figures
3.1 Caring and Handling measuring instruments
3. Underpinning 3.2 Calibrating and using measuring instruments
Skills 3.3 Performing calculation by Addition, Subtraction, Multiplication
and Division
3.4 Visualizing objects and shapes
3.5 Interpreting formula for volume, area, perimeter and other
geometric figures
The following resources MUST be provided:
4. Resource 4.1 Workplace location
Implications 4.2 Measuring instrument appropriate to servicing processes
4.3 Instructional materials relevant to the propose activity
Competency MUST be assessed through:
5. Method of 5.1 Observation with questioning
assessment 5.2 Written or oral examination
5.3 Interview
5.4 Demonstration with questioning
6. Context of 6.1 Competency elements must be assessed in a safe
assessment working environment
6.2 Assessment may be conducted in a workplace or
simulated environment
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
UNIT TITLE: READ, INTERPRET AND APPLY SPECIFICATION AND MANUALS.
UNIT CODE: ALT723203
UNIT DESCRIPTOR: This unit deals with identifying, interpreting and applying service
specification manuals, maintenance procedure manuals and periodic
maintenance manual.
ELEMENT PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1. Identify and 1.1 Appropriate manuals are identified and accessed as per job
access requirements.
manual/ 1.2 Version and date of manual is checked to ensure correct
specification specification and procedure are identified.
2. Interpret manuals 2.1 Relevant sections, chapters of manuals/specifications are
located in relations to the work to be conducted
2.2 Information and procedure in the manual are interpreted in
accordance to industry practices
3 Apply information 3.1 Manual is interpreted according to job requirements
in manual 3.2 Work steps are correctly identified in accordance with
manufacturer specification
3.3 Manual data is applied according to the given task
3.4 All correct sequencing and adjustments are interpreted in
accordance with information contained on the manual or
specifications
4. Store manuals 4.1 Manual or specification are stored appropriately to
ensure prevention of damage, ready access and
updating of information when required in accordance
with company requirements
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
RANGE OF VARIABLES
VARIABLE RANGE
Kinds of manuals:
1. Manuals 1.1 Manufacturer’s specification manual
1.2 Repair manual
1.3 Maintenance Procedure Manual
1.4 Periodic Maintenance Manual
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
EVIDENCE GUIDE
1.Critical aspects of Assessment requires evidence that the candidate:
competency 1.1 Identified and accessed manual/specification
1.2 Interpreted manuals
1.3 Applied information in manuals
1.4 Stored manuals
2. Underpinning 2.1 Types of manuals used in automotive industry
knowledge 2.2 Identification of symbols used in the manuals
2.3 Identification of units of measurements
2.4 Unit conversion
3. Underpinning 3.1.Reading and comprehension skills required to identify and
skills interpret automotive manuals and specifications
3.2 . Accessing information and data
The following resources MUST be provided:
4 Resource 4.1 All manuals/catalogues relative to Automotive
Implications 4.2 Job order, requisitions
4.3 Actual vehicle or simulator
Competency MUST be assessed through:
5 Method of 5.1 Observation with questioning
assessment 5.2 Interview
6 Context of 6.1 Assessment must be undertaken in accordance with
assessment the endorsed TESDA assessment guidelines
6.2 Assessment may be conducted in the workplace or a
simulated environment.
________________________________________________________________________________________________________________ 24
TR FOUNDRY MELTING/ CASTING NC II Promulgated
UNIT OF COMPETENCY : PERFORM SHOP MAINTENANCE
UNIT CODE : ALT723205
UNIT DESCRIPTOR : This unit deals with inspecting and cleaning of work area
including tools, equipment and facilities. Storage and checking
of tools/ equipment and disposal of used supplies/materials are
also incorporated in this competency.
PERFORMANCE CRITERIA
ELEMENT
Italicized terms are elaborated in the Range of Variables
1. Inspect/clean tools 1.1 Cleaning solvent used as per workshop/tools cleaning
and work area requirement
1.2 Work area is checked and cleaned
1.3 Wet surface/spot in work area is wiped and dried
2. Store/arrange tools 2.1 Tools/equipment are checked and stored in their
and shop equipment respective shelves/location
2.2 Corresponding labels are posted and visible
2.3 Tools are safely secured and logged in the records
3. Dispose wastes/used 3.1 Containers for used lubricants are visibly labeled
lubricants 3.2 Wastes/used lubricants are disposed as per workshop
SOP
4. Report damaged 4.1 Complete inventory of tools/equipment is maintained
tools/equipment 4.2 Damaged tools/equipment/facilities are identified and
repair recommendation is given
4.3 Reports prepared has no error/discrepancy
________________________________________________________________________________________________________________ 25
TR FOUNDRY MELTING/ CASTING NC II Promulgated
RANGE OF VARIABLES
VARIABLE RANGE
1. Work area Work areas include:
1.1 Workshop areas for servicing/repairing light and/or heavy
vehicle and/or plant transmissions and/or outdoor power
equipment
1.2 Open workshop/garage and enclosed, ventilated office area
1.3 Other variables may include workshop with:
Mess hall
Wash room
Comfort room
2. Cleaning 2.1 Cleaning solvent
requirement 2.2 Inventory of supplies, tools, equipment, facilities
2.3 List of mechanics/technicians
2.4 Rags
2.5 Broom
2.6 Mop
2.7 Pail
2.8 Used oil container
2.9 Oiler
2.10 Dust/waste bin
3. Manuals 3.1 Vehicle/plant manufacturer specifications
3.2 Company operating procedures
3.3 Industry/Workplace Codes of Practice
3.4 Product manufacturer specifications
3.5 Customer requirements
3.6 Industry Occupational Health and Safety
4. Company standard Wearing of Personal protective equipment include:
operating procedure 4.1 Gloves
4.2 Apron
4.3 Goggles
4.4 Safety shoes
________________________________________________________________________________________________________________ 26
TR FOUNDRY MELTING/ CASTING NC II Promulgated
EVIDENCE GUIDE
1. Critical aspects of Assessment requires evidence that the candidate:
competency 1.1 Cleaned workshop tools/facilities
1.2 Maintained equipment, tools and facilities
1.3 Disposed wastes and used lubricants/fluid as per required
procedure
2. Underpinning 2.1 5 S or TQM
knowledge and 2.2 Service procedures
attitudes 2.3 Relevant technical information
2.4 Safe handling of equipment and tools
2.5 Vehicle safety requirements
2.6 Workshop policies
2.7 Personal safety procedures
2.8 Fire extinguishers and prevention
2.9 Storage/disposal of hazardous/flammable materials
2.10 Positive Work Values (Perseverance, Honesty, Patience,
Attention to Details)
3. Underpinning skills 3.1 Handling/Storing of tools/equipment/supplies and material
3.2 Cleaning grease/lubricants
3.3 Disposing of wastes and fluid
3.4 Preparing inventory of s/m and tools and equipment
3.5 Monitoring of s/m and tools/equipment
4. Resource The following resources MUST be provided:
implications 4.1 Workplace: Real or simulated work area
4.2 Appropriate Tools & equipment
4.3 Materials relevant to the activity
5. Method of Competency MUST be assessed through:
assessment 5.1 Written/Oral Questioning
5.2 Demonstration
6. Context of 6.1 Competency must be assessed on the job or in a simulated
assessment environment.
6.2 The assessment of practical skills must take place after a
period of supervised practice and repetitive experience.
________________________________________________________________________________________________________________ 27
TR FOUNDRY MELTING/ CASTING NC II Promulgated
CORE COMPETENCIES
UNIT OF COMPETENCY: OPERATE MELTING FURNACES (N0N-ELECTRIC)
UNIT CODE: ALT812307
UNIT DESCRIPTOR: This unit covers operating a non electric metal melting furnace.
PERFORMANCE CRITERIA
ELEMENT
Italicized terms are elaborated in the Range of Variables
1. Select materials 1.1 Requisitions for materials are completed as required
according to standard operating procedures.
1.2 Charge analysis is undertaken in accordance with standard
operating procedures.
1.3 The charge analysis is converted to furnace charge weight
using standard operating procedures.
1.4 Charge is weighed according to standard operating
procedures.
2.1 Furnace is inspected for any defects or damage.
2. Start up furnace 2.2 Routine operational maintenance of furnace is undertaken
to standard operating procedures.
2.3 Furnace is started-up to standard operating procedures.
2.4 Faults are reported according to standard operating
procedures.
3.1 Emergency/safety procedures are identified and followed
3. Charge furnace as necessary.
3.2 Materials are pre-heated if required according to standard
operating procedures.
3.3 Materials are charged into furnace using standard operating
procedures.
3.4 Suitable areas for emergency unloading of molten metal are
identified and kept available.
________________________________________________________________________________________________________________ 28
TR FOUNDRY MELTING/ CASTING NC II Promulgated
4.1 Furnace is maintained at optimum operating condition to
4. Monitor furnace standard operating procedures.
4.2 Sample for chemical analysis is taken and remedial action is
applied as required to correct composition using standard
operating procedures.
4.3 Dross or slag is removed from furnace per standard
operating procedures.
4.4 If necessary, metal in the furnace is de-gassed to standard
operating procedures.
4.5 Temperature of metal is checked and adjustment made if
necessary.
5.1 Quantity of the required metal is identified.
5. Tap or unload the 5.2 Tap rate is carried out to standard operating procedures.
furnace 5.3 Tapping or unloading is undertaken and completed safely
according to standard operating procedures.
6.1 Shut-down of furnace is completed to standard operating
6. Shut down furnace procedures.
6.2 Routine operational maintenance of furnace is undertaken to
standard operating procedures.
________________________________________________________________________________________________________________ 29
TR FOUNDRY MELTING/ CASTING NC II Promulgated
RANGE OF VARIABLE
VARIABLE RANGE
1. Materials Type of alloy to be melted.
1.1 Aluminum
1.2 Bronze
1.3 Brases
1.4 Magnesium Alloy
2. Furnace 2.1 Singular
2.2 Multi-fuel
2.3 Oil fired
2.4 Gas fired
3. Routine 3.1 Routine lubrication
Operational 3.2 Cleaning
maintenance 3.3 Routine repair
3.4 Repairing of refractory lining
4. Faults 4.1 Leaks in crucible
4.2 Clogged burner
4.3 Damage crucible
5. Emergency/safety 5.1 Tapped out
procedures 5.2 Cleaning of burner
5.3 Repair
________________________________________________________________________________________________________________ 30
TR FOUNDRY MELTING/ CASTING NC II Promulgated
EVIDENCE GUIDE
1. Critical aspects of Assessment requires evidence that the candidate:
competency 1.1 Selected materials
1.2 Started up furnace
1.3 Charged furnace
1.4 Monitored furnace
1.5 Tapped or unloaded the furnace
1.6 Shut down furnace
2. Underpinning 2.1 Types of manuals used in the automotive foundry industry
knowledge and 2.2 Identification of symbols used in the manuals forms
attitudes and standard operating procedures
2.3. Identification of units of measurements and unit of
conversion
2.4 Sampling procedures for chemical analysis, carbon equivalent
and chill wedge tests
2.5 Procedures for de-gassing as necessary using tablets or lance
and other methods.
2.6 Procedures and principles of de-slagging or dross removal
2.7 Tapping temperature and procedure of the molten metal
2.8 Weighing procedures using different scale types
2.9 Correct order of loading of different charge materials
2.10 Thermocouple condition monitoring and adjustment
mechanism for furnace,
2.11 Furnace close-down procedures
2.12 Applicable industry safety standards, national standards,
OHSA guides, Philippine codes of practice/standards, use and
application of personal protective equipment safe work
practices and procedures
3.1 Reading and interpreting routine information on written job
3. Underpinning instructions, specifications, standard operating procedures
skills relevant test data sheets and other standard workplace forms.
May include drawings for furnace operation
3.2 Following oral instruction and entering routine and familiar
information onto proformas and standard workplace forms.
3.3 Identifying faults and areas for routine repair of the furnace and
performing routine maintenance as necessary.
3.4 Following procedures for starting and closing down the furnace
3.5 Deciding on charge materials, weighing them and feeding the
charge materials into the furnace.
3.6 Measuring metal temperature and correcting as necessary
3.7 Sampling for chemical analysis, carbon equivalent and chill
wedge tests
3.8 Degassing as necessary using tablets or lance and other
methods.
3.9 Deslagging or dross removal
3.10Tapping temperature and procedure of the molten metal
3.11Weighing procedures using different scale types
3.12Correct order of loading of different charge materials
________________________________________________________________________________________________________________ 31
TR FOUNDRY MELTING/ CASTING NC II Promulgated
The following resources MUST be provided:
4. Resource 4.1 All manuals/catalogues relative to Melting/Casting
implications 4.2 Job order, requisitions slip for materials
4.3 Materials, tools and equipment relevant to the activity
4.4 Actual furnace
Competency MUST be assessed through:
5. Method of 5.1 Observation with questioning
assessment 5.2 Demonstration with questioning
5.3 Interview
5.4 Portfolio
6.1 Assessment must be undertaken in accordance with
6. Context of the endorsed TESDA assessment guidelines
assessment 6.2 Assessment may be conducted in the workplace or a
simulated environment.
________________________________________________________________________________________________________________ 32
TR FOUNDRY MELTING/ CASTING NC II Promulgated
UNIT OF COMPETENCY: OPERATE CUPOLA MELTING FURNACES
UNIT CODE: ALT812308
UNIT DESCRIPTOR: This unit covers operating a cupola metal melting furnace for cast iron.
PERFORMANCE CRITERIA
ELEMENT
Italicized terms are elaborated in the Range of Variables
1. Select materials 1.1 Charges are computed for the required metal composition
needed as per standard operating procedures.
1.2 The charge computation is converted to furnace charge weight
using standard operating procedures.
1.3 Charge is weighed according to standard operating procedures.
2. Start up furnace 2.1 Furnace is inspected for any defects or damage.
2.2 Routine operational maintenance of furnace is undertaken to
standard operating procedures.
2.3 Fuel (coke) is charge into the cupola furnace and fired up with a
fire starter according to standard operating procedures.
2.4 Additional fuel is added to the initial volume according to
standard operating procedures and until the right level is reached.
3. Charge furnace 3.1 Safety/emergency procedures are identified and followed as
necessary.
3.2 Materials are prepared. Scrap metal are cut to required size,
cleaned and dried.
3.3 Materials are charged into furnace using standard operating
procedures. Charges are arranged in layers, in sequence of coke,
limestone and metal scrap.
4. Monitor furnace 4.1 Furnace is operated at optimum condition according to standard
operating procedures.
4.2 Sample for chemical analysis is taken and remedial action is
applied as required according to standard operating procedures.
4.4 Temperature of metal is checked and adjustment made
according to standard operating procedures if necessary.
5.1 Quantity of the required metal is computed and determined.
5. Tap the furnace 5.2 Tapping is carried out according to standard operating
procedures.
5.3 Tapping is undertaken and completed safely according to
standard operating procedures.
6.1 Shut-down of furnace is completed according to standard
6. Shut down operating procedures and when all the metal have been tapped,
furnace 6.2 Routine operational maintenance of furnace is undertaken to
standard operating procedures.
7.1 Bottom of furnace is opened and all loads are dropped.
7. Cool down 7.2 Air blast is introduced to cool down the furnace
furnace 7.3 Cupola hearth is inspected once the furnace is cooled and repair
of lining is undertaken.
________________________________________________________________________________________________________________ 33
TR FOUNDRY MELTING/ CASTING NC II Promulgated
RANGE OF VARIABLE
VARIABLE RANGE
1. Routine 1.1 Routine lubrication
operational 1.2 Blower maintenance
maintenance 1.3 Cleaning
1.4 Routine repair
1.5 Replacement of refractory
2. Materials 2.1 Fire brick
2.2 Mortar clay
2.3 Fire clay
2.4 Silica sand
2.5 Coko
2.6 Return scrap
2.7 Purchase scrap
2.8 Ferrous Alloy
2.9 Lime stone
________________________________________________________________________________________________________________ 34
TR FOUNDRY MELTING/ CASTING NC II Promulgated
EVIDENCE GUIDE
1. Critical aspects of Assessment requires evidence that the candidate
competency 1.1 Selected materials
1.2 Started up furnace
1.3 Charged furnace
1.4 Monitored furnace
1.5 Tapped the furnace
1.6 Shut down furnace
1.7 Cooled down furnace
2. Underpinning 2.1 Types of manuals used in the automotive foundry.
knowledge and industry
attitudes 2.2 Identification of symbols used in the manuals forms
and standard operating procedures
2.3. Identification of units of measurements and unit of
conversion
2.4 Sampling procedures for chemical analysis, carbon equivalent
and chill wedge tests
2.5 Procedures for de-gassing as necessary using tablets or lance
and other methods.
2.6 Procedures and principles of de-slagging or dross removal
2.7 Tapping temperature and procedure of the molten metal
2.8 Weighing procedures using different scale types
2.9 Correct order of loading of different charge materials
2.10 Thermocouple condition monitoring and adjustment
mechanism for furnace,
2.11 Furnace close-down procedures
2.12 Applicable industry safety standards, national standards,
OHSA guides, Philippine codes of practice/standards, use and
application of personal protective equipment safe work
practices and procedures
2.13 Hazards and control measures associated with operating
melting furnaces
3. Underpinning 3.1 Identified and accessed manual/specification
skills 3.2 Interpreted manuals
3.3 Applied information in manuals
3.4 Stored manuals
3.5 Reading and interpreting routine information on written job
instructions, specifications, standard operating procedures
relevant test data sheets and other standard workplace forms
and drawings for furnace operation
3.6 Entering routine and familiar information onto
3.7 Proformas and standard workplace forms.
3.8 Identifying faults and areas for routine repair of the furnace and
performing routine maintenance as necessary.
3.9 Following procedures for starting and closing down the
furnace.
3.10 Deciding on charge materials weighing charge materials
feeding materials into furnace
3.11 Measuring metal temperature and correcting as
necessary
________________________________________________________________________________________________________________ 35
TR FOUNDRY MELTING/ CASTING NC II Promulgated
4. Resource The following resources MUST be provided:
implications 4.1 All manuals/catalogues relative to Melting/Casting
4.2 Job order, requisitions slip for materials
4.3 Materials, tools and equipment relevant to the activity
4.4 Actual furnace
5. Method of Competency MUST be assessed through:
assessment 5.1 Observation with questioning
5.2 Demonstration with questioning
5.3 Interview
5.4 Portfolio
6. Context of 6.1 Assessment must be undertaken in accordance with
assessment the endorsed TESDA assessment guidelines
6.2 Assessment may be conducted in the workplace or a
simulated environment.
________________________________________________________________________________________________________________ 36
TR FOUNDRY MELTING/ CASTING NC II Promulgated
UNIT OF COMPETENCY: OPERATE AN ELECTRIC INDUCTION MELTING FURNACES
UNIT CODE: ALT812309
DESCRIPTOR : This unit covers operating an electric furnace for melting of ferrous
metals.
ELEMENT PERFORMANCE CRITERIA
1. Select materials 1.1 Material requisitions are prepared according to standard
operating procedures / Job instructions.
1.2 Charge analysis is undertaken in accordance with
standard operating procedures.
1.3 The charge analysis is converted to furnace charge
weight using standard operating procedures.
1.4 Charge is weighed according to standard operating
procedures.
2. Start up furnace 2.1 Furnace is inspected for any defects or damage.
2.2 Routine operational maintenance of furnace is
undertaken to standard operating procedures.
2.3 Furnace is started up to standard operating procedures.
2.4 Faults are reported according to standard operating
procedures.
3.1 Emergency/safety procedures are identified and observed
3. Charge furnace / followed as necessary.
3.2 Materials are pre-heated (if required) according to
standard operating procedures.
3.3 Materials are charged into furnace using standard
operating procedures.
3.4 Suitable areas for emergency unloading of molten metal
are identified and kept available.
4.1 Furnace is maintained at optimum operating condition to
4. Monitor furnace standard operating procedures.
4.2 Sample for chemical analysis is taken and remedial action
is applied as required to standard operating procedures.
4.3 Furnace is drossed and/or de-slagged to standard
operating procedures.
4.4 Temperature of metal is checked and adjustment made if
necessary.
5.1 Pouring ladles repaired / pre-heated.
5. Tap or unload the 5.2 Quantity of the required metal is identified.
furnace 5.3 Tap rate is carried out to standard operating procedures.
5.4 Tapping or unloading is undertaken and completed safely
according to standard operating procedures.
6.1 Shut-down of furnace is completed to standard operating
6. Shut down furnace procedures.
6.2 Routine operational maintenance of furnace is
undertaken to standard operating procedures.
________________________________________________________________________________________________________________ 37
TR FOUNDRY MELTING/ CASTING NC II Promulgated
RANGE OF VARIABLES
VARIABLE RANGE
1. Materials Type of alloy to be melted.
1.1 Gray cast iron and its alloys
1.2 Low / Medium carbon steel
1.3 High alloy carbon steel
1.4 Stainless steel
1.5 Aluminum and its Alloy
1.6 Copper Alloy
2. Furnace 2.1 High Frequency
2.2 Low Frequency
2.3 Medium Frequency
2.4 Type of lining refractory
3. Routine 3.1 Routine repair
Operational 3.2 Patching of refractory
Maintenance 3.3 Routine cleaning
3.4 Lubrication
3.5 Make-up water adjustment
________________________________________________________________________________________________________________ 38
TR FOUNDRY MELTING/ CASTING NC II Promulgated
EVIDENCE GUIDE
1. Critical aspect of Assessment requires evidence that the candidate:
competency 1.1 Selected materials
1.2 Started up furnace
1.3 Charged furnace
1.4 Monitored furnace
1.5 Tapped or unloaded the furnace
1.6 Shut down furnace
2. Underpinning 2.1 Types of manuals used in the automotive foundry.
knowledge and industry
attitudes 2.2 Identification of symbols used in the manuals forms
and standard operating procedures
2.3. Identification of units of measurements and unit of
conversion
2.2 Sampling procedures for chemical analysis, carbon
equivalent and chill wedge tests
2.5 Procedures for de-gassing as necessary using tablets or
lance and other methods.
2.6 Procedures and principles of slag or dross removal
2.7 Tapping temperature and procedure of the molten metal
Weighing procedures using different scale types
2.8 Correct order of loading of different charge materials
2.9 Thermocouple condition monitoring and adjustment
mechanism for furnace,
2.10 Furnace close-down procedures
2.11 Applicable industry safety standards, national standards,
OHSA guides, Philippine codes of practice/standards, use
and application of personal protective equipment safe work
practices and procedures
________________________________________________________________________________________________________________ 39
TR FOUNDRY MELTING/ CASTING NC II Promulgated
3. Underpinning 3.1 Reading and interpreting routine information on written job
skills instructions, specifications, standard operating procedures
relevant test data sheets and other standard workplace
forms or drawings for furnace operation
3.2 Following oral instruction and entering routine and familiar
information onto proformas and standard workplace forms.
3.3 Identifying faults and areas for routine repair of the furnace
and performing routine maintenance as necessary.
3.4 Following procedures for starting and closing down the
furnace
3.5 Deciding on charge materials, weighing them and feeding
the charge materials into the furnace.
3.6 Measuring metal temperature and correcting as necessary
3.7 Sampling for chemical analysis, carbon equivalent and
chill wedge tests
3.8 Degassing as necessary using tablets or lance and other
methods.
3.9 Deslagging or dross removal
3.10 Tapping temperature and procedure of the molten metal
3.11 Correct order of loading of different charge materials
3.12 Thermocouple condition monitoring and adjustment
mechanism for furnace
3.13 Operating temperature measurement instruments
3.14 Repair / lining of furnace lining refractory
3.15 Operating re-lining tools
3.16 Reading of measuring tools, i.e. steel rule, plumb bulb,
outside caliper, etc.
3.17 Operating over-head crone
3.18 Operating fork-lifts
3.19 Operating cooling curve analysis
3.20 Operating weigh scales
4. Resource The following resources MUST be provided:
implications 4.1 All manuals/catalogues relative to coreless induction furnace.
4.2 Job order, requisitions
4.3 Actual furnace and operations
5. Method of Competency MUST be assessed through:
assessment 5.1 Observation with questioning
5.2 Demonstration with questioning
5.3 Interview
5.4 Portfolio
6. Context of 6.1 Assessment must be undertaken in accordance with
assessment the endorsed TESDA assessment guidelines
6.2 Assessment may be conducted in the workplace or a
simulated environment.
________________________________________________________________________________________________________________ 40
TR FOUNDRY MELTING/ CASTING NC II Promulgated
UNIT OF COMPETENCY: FETTLE AND TRIM METAL CASTINGS
UNIT CODE: ALT812310
UNIT DESCRIPTOR: This unit covers fettling and trimming metal castings and
assessing the quality of the casting.
PERFORMANCE CRITERIA
ELEMENT
Italicized terms are elaborated in the Range of Variables
1.1 Job requirements are correctly determined from instructions
1. Determine job and specifications.
requirements 1.2 Correct moldings and/or castings are located and arranged
for efficient processing.
2.1 Personal protective equipment is selected and used
2. Observe safety correctly.
requirements 2.2 Castings are handled using manual or mechanical handling
methods appropriate to the task.
2.3 Castings/forgings are stored or positioned in a safe manner.
3.1 Casting is removed from mold and/or sand media is removed
3. Identify excess from casting as required.
material for removal 3.2 Castings are visually checked as suitable for further
processing, and excess metal is correctly identified
according to standard operating procedures.
4.1 Cleaning method is selected appropriate to casting and job
4. Select correct tools requirements.
and equipment 4.2 Rumbling/shot blast/sand blast equipment is set to
specification and used in accordance with standard
operating procedures as required.
4.3 Appropriate hand tools are selected and used for the given
task.
4.4 Appropriate power tools and accessories are selected and
used for the given task.
5.1 Excess metal (e.g. runners, risers and flashing) is removed
5. Remove excess using methods and equipment appropriate to the task and to
material standard operating procedures.
5.2 Excess metal suitable for recycling is identified according to
standard operating procedures.
5.3 Excess metallic materials are identified from specifications
and isolated as required according to standard operating
procedures.
6.1 Castings are visually checked for conformance with
6. Quality assess specifications to standard operating procedures.
castings/forgings 6.2 Non-conforming castings are rejected or set aside and
identified for further consideration or remedial action
according to standard operating procedures.
6.3 Faults are reported/recorded as required according to
standard operating procedures.
________________________________________________________________________________________________________________ 41
TR FOUNDRY MELTING/ CASTING NC II Promulgated
RANGE OF VARIABLES
VARIABLE RANGE
1. Personal 1.1 Safety goggles
protective 1.2 Apron
equipment 1.3 Gloves
1.4 Safety shoes
2.1 Files
2. Hand tools 2.2 Chisels
2.3 Hammers, etc.
3. Power tools and 3.1 Saws
Equipment 3.2 Croppers
3.3 Grinding disks/belts (including grades)
3.4 Swing grinder
3.5 Pedestal grinders etc.
3.6 Hanger type blast machine
3.7 Shot thumblast machine
3.8 Table type shot blasting machine
________________________________________________________________________________________________________________ 42
TR FOUNDRY MELTING/ CASTING NC II Promulgated
EVIDENCE GUIDE
Assessment requires evidence that the candidate:
1. Critical aspects
of competency 1.1 Performed fettling and trimming metal castings.
1.2 Operated grinding machines and cutting equipment.
1.3 Operated shot blasting machines.
2. Underpinning 2.1 Characteristic of quality fettling standards for metal casting/forging
knowledge and 2.2 Fettling requirements
attitudes 2.3 Different fettling tools and their usage
2.4 Handling procedure and storage requirements of materials tools
and equipment
2.5 Use and application of personal protective equipment
2.6 Safe work practices and procedures
2.7 Hazards and control measures associated with fettling
and trimming metal castings
3 Underpinning 3.1 Interpreting written instruction sketches and drawings
skills 3.2 Identifying castings
3.3 Visually inspecting castings
3.4 Fettling and trimming metal castings
3.5 Conducting a final inspection
3.6 Recording and reporting associated with fettling and trimming metal
castings
3.7 Handling materials, tools and equipment
The following resources MUST be provided:
4. Resource 4.1 All manuals/catalogues relative to coreless induction furnace.
implications 4.2 Job order, requisitions
4.3 Actual furnace and operations
Competency MUST be assessed through:
5. Method of 5.1 Observation with questioning
assessment
5.2 Demonstration with questioning
5.3 Interview
5.4 Portfolio
6.1 Assessment must be undertaken in accordance with
6. Context of the endorsed TESDA assessment guidelines
assessment
6.2 Assessment may be conducted in the workplace or a
simulated environment.
________________________________________________________________________________________________________________ 43
TR FOUNDRY MELTING/ CASTING NC II Promulgated
UNIT OF COMPETENCY: PERFORM REFRACTORY INSTALLATION
AND REPAIR
UNIT CODE : ALT812311
UNIT DESCRIPTOR: This unit covers repairing and installing/replacing refractory.
ELEMENT PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1.1 Specification is interpreted and understood.
1. Inspect refractory 1.2 Specific areas of the refractory are identified for repair or
replacement.
2.1 Sequence of operations to remove refractory is determined to
2. Knock out refractory meet the job specification.
2.2 Appropriate tools and equipment are selected to safely
remove damaged refractory.
2.3 Damaged refractory is removed and disposed of safely.
3. Prepare refractory 3.1 Appropriate refractory materials are selected to meet
materials specifications.
3.2 Refractory media is mixed to specification.
4. Install refractory 4.1 Sequence of operations to install refractory is determined to
meet the job specification.
4.2 Installation of refractory is performed in accordance to
standard operating procedures and techniques to meet the job
specification. using appropriate tools and equipment
5. Cure refractory 5.1 Refractory is cured to specifications using appropriate
techniques and equipment to meet the job specification.
________________________________________________________________________________________________________________ 44
TR FOUNDRY MELTING/ CASTING NC II Promulgated
RANGE OF VARIABLES
VARIABLE RANGE
1. Specific area of 1.1 Heat insulating materials used inside molten metal vessels and
refractory includes material which can be machine rammed, hand rammed,
forked or vibrated
1.2 Refractory bricks
1.3 Fiberboard
2. Tools and
Tools
equipment
2.1 Paint brush
2.2 Brooms
2.3 Chisel
Equipment
2.4 Mixer
2.5 Scissors
2.6 Steel tape
3.Installation of
3.1 Hand ramming
refractory
3.2 Machine ramming
3.3 Internal vibration
3.4 External vibration
________________________________________________________________________________________________________________ 45
TR FOUNDRY MELTING/ CASTING NC II Promulgated
EVIDENCE GUIDE
1. Critical aspects Assessment requires evidence that the candidate:
of competency 1.1 Repaired and installed/replaced all types of refractory.
2.1 Requirements repair or replacement
2. Underpinning
Inspection techniques
knowledge and
2.2 Mixing, installing and curing techniques and equipment
attitudes
2.3 OH&S legislation and EPA regulations applying to
working with refractory
2.4 Use and application of personal protective equipment
2.5 Safe work practices and procedures
2.6 Hazards and control measures associated with refractory
installation and repair
3 Underpinning 3.1 Interpreting job specifications and other applicable
skills reference documents
3.2 Planning and sequencing operations
3.3 Inspecting and identifying faults
3.4 Removing damaged refractory safely
3.5 Mixing refractory correctly
3.6 Installing refractory correctly
3.7 Curing refractory correctly
3.8 Following oral instructions
3.9 Handling materials
3.10 Recording and reporting associated with to repair and
install/replace of all types of refractory
The following resources MUST be provided
4.1 All tools, equipment, materials required.
4 Resource
implications 4.2 All relevant workplace procedures, product and manufacturing
specifications, codes, standards, manuals and reference
materials
4.3 Refractory facility
5. Method of Competency MUST be assessed through:
assessment 5.1 Observation with questioning
5.2 Demonstration with questioning
5.3 Interview
5.4 Portfolio
6. Context of 6.1 Assessment must be undertaken in accordance with
assessment the endorsed TESDA assessment guidelines
6.2 Assessment may be conducted in the workplace or a
simulated environment.
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UNIT OF COMPETENCY: USE AND MAINTAIN MEASURING INSTRUMENT
UNIT CODE: ALT821303
UNIT DESCRIPTOR: This unit identifies the competence required to measure components
or sections using non-specialist instrument and maintain the
measuring instrument.
ELEMENT PERFORMANCE CRITERIA
Italicized terms are elaborated in the Range of Variables
1.1 Measurement of dimensions and variables are completed
1. Measure without causing damage to any instrument or components
dimensions or 1.2 Appropriate measuring instrument is selected
variables using 1.3 Relevant measuring techniques are used and results
appropriate appropriately recorded
instrument 1.4 All measuring activities are carried out according to industry
regulations/guidelines OHS & requirements and
enterprise/procedures policies
2.1 Maintenance of measuring instrument is achieved without
causing damage to any instrument or component
2. Maintain measuring 2.2 Routine care and storage of measuring instrument is
instrument undertaken according to manufacture specifications
2.3 Checking and calibrating of measuring devices is done prior to
use.
2.4 All maintenance activities of measuring instruments are carried
out according to industry regulations/guidelines OHS
legislation, and enterprise procedures policies
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RANGE OF VARIABLES
VARIABLE RANGE
1. Dimension and 1.1 Measuring Tape
variables Diameter of Furnace components
External Dimensions
measurement
1.2 Steel Rule
Straightness
Alignment
1.3 Leveling Gauge
Warpage
Level and angle
1.4 Pyrometer
2. Measuring 2.1 Handtools
instrument and 2.2 Depth gage
tools 2.3 Vernier Caliper
2.4 Straight edge
2.5 Feeler gage
2.6 Inside Caliper
2.7 T-squares
2.8 Flat edges
2.9 Dividers
2.10 Protractors
3. Measuring 3.1 Correct usage of the above mentioned measuring
technique instrument and tools.
3.2 Out of round or ovality
3.3 Cylindricity or taper conicity
4. OHS 4.1 Wearing of personal protective instrument such as
Requirements apron, goggles, gloves, safety shoes
4.2 Disposal of wastes materials
4.3 Workshop housekeeping
5. Routine care 5.1 Periodic check up of pyrometer with standard bars
and storage of 5.2 Storage in box separated from hand tools
measuring 5.3 Proper handling
5.4 Not to exposed to liquid such as water.
instrument
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EVIDENCE GUIDE
Assessment requires evidence that the candidate:
1. Critical aspects
1.1 Measured components or section using correct instrument.
competency 1.2 Maintained measuring instrument.
2. Underpinning 2.1 Personal and instrument safety requirements
2.2 Measuring instrument types and their application
knowledge and 2.3 Measuring procedures
attitudes 2.4 Measuring instrument graduation
2.5 Measuring instrument maintenance procedures
2.6 Positive Work values ( Perseverance, Patience,
Honesty, Attention to Details)
3. Underpinning 3.1 Accessing, interpreting and applying technical
skills information
3.2 Using tools and instrument correctly and safely
3.3 Maintain measuring instrument
2.1 Using measuring instrument
The following resources must be provided:
3 Resource
4.1 Workplace: Real or simulated work area
implications 4.2 Appropriate Tools & instrument
4.3 Materials relevant to the activity
4 Method of Competency must be assessed through
assessment 5.1 Demonstration of skills in measurement of length, squareness,
flatness, angles, roundness, depth, clearance or any
measurements that can be taken from analogue or digital devices.
5.2 Written examination
5 Context of 6.1 The assessment of practical skills must only take place after a
assessment period of supervised practice and repetitive experience in a safe
working environment. If workplace conditions are not available,
assessment in simulated workplace conditions is acceptable.
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SECTION 3 TRAINING STANDARDS
These guidelines are set to provide the Technical and Vocational Education and
Training (TVET) providers with information and other important requirements to consider
when designing training programs for Foundry Melting/Casting NC II
3.1 CURRICULUM DESIGN
Course Title: Foundry-Melting/Casting NC Level: NC II
Nominal Training Duration: 18 Hours (Basic Competencies)
20 Hours (Common Competencies)
90 Hours (Core Competencies)
Course Description:
This course is designed to equip individual the competencies that a person must achieve
to be able to melt different kinds of metals, cast it using different operations and different
furnaces or heating systems and fuel. It also includes fettling and cleaning; ability to inspect,
measure and interpret drawings; set up and operate variety of specialized furnaces; use
appropriate measuring instrument in operating and maintaining the melting equipment and
perform repair.
This course is also designed to provide basic and common skills to equip individual with
operational skills in foundry-melting/casting.
To obtain this, all units prescribed for this qualification must be achieved.
BASIC COMPETENCIES
Unit of Assessment
Learning Outcomes Methodology
Competency Approach
1. Participate in 1.1 Obtain and convey Group discussion Written test
workplace workplace information. Interaction Practical/perform
communication 1.2 Complete relevant work ance test
related documents. Interview
1.3 Participate in workplace
meeting and discussion.
2. Work in a team 2.1 Describe and identify Discussion Observation
environment team role and Interaction Simulation
responsibility in a team. Role playing
2.2 Describe work as a team
member.
3. Practice career 3.1 Integrate personal Group Discussion Demonstration
professionalism objectives with Interaction Observation
organizational goals. Interviews/
3.2 Set and meet work questioning
priorities.
3.3 Maintain professional
growth and
development.
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4. Practice 4.1Identify hazardous risks Discussion Observation
occupational 4.2 Evaluate hazard and Plant tour Interview
health and risks Symposium
safety 4.3 Control hazards and
risks
4.4 Maintain occupational
health and safety
awareness
COMMON COMPETENCIES
Unit of Assessment
Learning Outcomes Methodology
Competency Approach
1. Read, Interpret 1.1 Identify and access Lecture/ Direct observation
and Apply engineering drawings/ Demonstration Interview
Engineering specification Dual training
Drawings 1.2.Interpret drawings
1.3.Apply information in
the drawings &
specifications
1.4 Store drawings
2. Perform 2.1. Select measuring Lecture/ Written test
Mensuration instrument and Demonstration Oral questioning
and 2.2 Carry out Simulation Direct observation
Calculation measurement and Exercises
calculations.
2.3. Maintain measuring
instruments
3. Read, Interpret 4.1. Identify/accessed Lecture/ Written test
and Apply manuals and interpret Demonstration Direct observation
Specifications data and specification Dual training Project method
and Manual 4.2 Apply information Distance Learning Interview
accessed in manual
4.3 Store manual
5. Perform Shop 5.1 Inspect/clean tools and Lecture/ Written test
Maintenance work area Demonstration Direct observation
5.2 Store/arrange tools and Dual training Demonstration
shop equipment Self paced (modular) Interview
5.3 Dispose wastes/used Simulation
lubricants
5.4 Report damaged
tools/equipment
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CORE COMPETENCIES
Unit of Assessment
Learning Outcomes Methodology
Competency Approach
1. Operate Melting 1.1 Select materials Lecture/ Observation with
Furnaces (Non 2.2 Start up non- electric Demonstration Questioning
Electric) furnace Dual training Demonstration of
3.3 Charge non-electric practical skills
furnace Interview
4.4 Monitor non-electric Portfolio
furnace
5.5 Tap or unload the
furnace
6.6 Shut down furnace
2. Operate Cupola 2.1 Select materials Lecture/ Observation with
Melting 2.2 Start up Cupola Demonstration Questioning
Furnaces furnace Dual training Demonstration of
2.3 Charge Cupola practical skills
furnace’ Interview
2.4 Monitor cupola Portfolio
furnace
2.5 Tap the furnace
2.6 Shut down cupola
furnace
2.7 Cool down cupola
furnace
3. Operate an 3.1 Furnace Select Lecture/ Observation with
Electric materials Demonstration Questioning
Induction 3.2 Start up Electric Dual training Demonstration of
Melting Furnace Induction Melting practical skills
3.3 Charge Electric Interview
Induction Furnace Portfolio
3.4 Monitor furnace
3.5 Tap and unload
furnace
3.6 Shot down furnace
4. Fettle and Trim 4.1 Determine job Lecture/ Observation with
Metal Casting / requirements to fettle Demonstration Questioning
Forgings and trim metal Dual training Demonstration of
casting/forging practical skills
4.2 Observe safety Interview
requirements Portfolio
4.3 Identify excess
material for removal
4.4 Select correct tools
and equipment
4.5 Remove excess
material
4.6 Quality assess
castings/forgings
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5. Perform 5.1 Inspect refractory Lecture/ Observation with
Refractory 5.2. Knock out refractory Demonstration Questioning
Installation and 5.3. Prepare refractory Dual training Demonstration of
Repair materials practical skills
5.4. Install refractor Interview
5.5. Cure refractory Portfolio
6. Use and 6.1 Measure dimensions Lecture/ Observation with
Maintain or variables using Demonstration Questioning
Measuring appropriate Dual training Demonstration of
Instruments instruments practical skills
6.2 Maintain measuring Interview
instruments Portfolio
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3.2 TRAINING DELIVERY
The delivery of training should adhere to the design of the curriculum. Delivery
should be guided by the 10 basic principles of competency-based TVET.
The training is based on curriculum developed from the competency standards;
Learning is modular in its structure;
Training delivery is learner-centered and should accommodate individualized
and self-paced learning strategies;
Training is based on work that must be performed;
Training materials are directly related to the competency standards and the
curriculum modules;
Assessment is based in the collection of evidence of the performance of work to
the industry required standard;
Training is based on and off-the-job components;
Allows for recognition of prior learning (RPL) or current competencies;
Training allows for multiple entry and exit; and
Approved training programs are nationally accredited.
The competency-based TVET system recognizes various types of delivery
modes, both on and off-the-job as long as the learning is driven by the competency
standards specified by the industry. The following training modalities may be adopted
when designing training programs:
The dualized mode of training delivery is preferred and recommended. Thus
programs would contain both in-school and in-industry training or fieldwork
components. Details can be referred to the Dual Training System (DTS)
Implementing Rules and Regulations.
Modular/self-paced learning is a competency-based training modality wherein
the trainee is allowed to progress at his own pace. The trainer facilitates the
training delivery
Peer teaching/mentoring is a training modality wherein fast learners are given
the opportunity to assist the slow learners.
Supervised industry training or on-the-job training is an approach in training
designed to enhance the knowledge and skills of the trainee through actual
experience in the workplace to acquire specific competencies prescribed in the
training regulations.
Distance learning is a formal education process in which majority of the
instruction occurs when the students and instructor are not in the same place.
Distance learning may employ correspondence study, or audio, video or
computer technologies.
Project-Based Instruction is an authentic instructional model or strategy in which
students plan, implement and evaluate projects that have real world
applications.
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3.3 TRAINEE ENTRY REQUIREMENTS
This section specifies the qualifications of trainees and educational
experience. Other requirements like health and physical requirements are also
stated. Passing entry written examinations may also be indicated if necessary.
With experience in basic machining
With good moral character;
Ability to communicate both oral and written; and
Physically and mentally fit
3.4 LIST OF TOOLS, EQUIPMENT AND MATERIALS
FOUNDRY MELTING/CASTING NC II
Recommended list of tools, equipment and materials for the training of 12 trainees for
Foundry Melting/Casting NC II
TOOLS EQUIPMENT MATERIALS
QTY QTY QTY
2 sets Box wrench 1 unit Melting furnace 2 tons Aluminum Alloy
(non-electric)
2 sets Open end 1 unit Cupola melting 500Kg Copper Alloy
wrench furnace s
2 sets Socket wrench 1 unit Induction melting 200Kg Magnesium Alloy
furnace s
2 pcs Adjustable 1 unit Shot hanger blast 50Kgs Zinc
wrench machine
2 sets Screwdriver (+) 1 unit Table blast 50Kgs Tin
machine
2 sets Screwdriver (-) 1 unit Thumb blast 50Kgs Lead
machine
2 pcs Plier (side 1 unit Pedestal grinder 2 tons Pig Iron
cutting) (double head)
2 pcs Plier (long nose) 1 unit Shake out machine 2 tons Return scrap
2 pcs Mechanical plier 1 unit Swing grinder 2 tons Steel scrap
2 pcs Ballpein hammer 1 set Refractory ramming 100Kg Carburizer
tools s
4 pcs Wood mallet 1 unit Immersion type 30Kgs Ferro silicone
Termo-couple
(1300 C° min.)
4 pcs Claw hammer 5 Transfer ladle 30Kgs Ferro manganese
sets
1 set Feeler gauge 1 Weighing scale (10, 50Kgs Ferro chrome
unit 50, 100, 500, 1000
each Kgs capacity)
2 pcs Hammer (plastic 1 unit Charging hoist (1 20 Kgs Slag coagelants
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
faced) ton capacity)
1 set Number punch 2 Charging box 500Kg Acid lining
units (200Kgs capacity) s
1 set Alphabet punch 1 unit Optical Pyro-meter 500Kg Neutral lining
(for ferrous metals) s
1 set Straight drill 1 unit Cooling curve 2 Mica 4”x8”
analyzer (with sheets
sample pedestal)
2 pcs Ballpein hammer 1 unit Forehearth (1 ton 2 Asbestos board 4”x8”
(5lbs) capacity) sheets
12 pcs Goggles 1 unit Chill mold (wedge) 200Kg Mortar clay
s
12 pcs Helmet 1 unit Chill mold (ASTN 200Kg Fire clay
2C) s
12 pcs Safety Shoes 1 unit Angle grinder (6 10 De-gasser
inches) tablets
1 pc Straight edge 2 Portable grinder 10 Silicone modifier
(1000 mm long) units (pencil type) tablets
1 pc Tri-square 1 set A-crane (500Kgs 10 Kgs Titanium boron grain
(300mm long) capacity) refiner
1 pc Adjustable 2 MS plate (2.3mm 2 Kgs Melt cover
protractor sets thick)
2 sets Colored goggles 2 BI pipe (1 1/2 “ dia) 500Kg Foundry coke
lengt s
hs
1 pc Sledge hammer 2 CRS shafting 16 50Kgs Limestone
lengt dia
hs
20 Wire rope (1/2 dia) 10 Kgs Inoculant
mete
rs
2 pcs File (coarse) half 20Kgs Ferro silicon
round magnesium
2 pcs File (fine) half 50pcs Cooling curve
round analyzer mold
1 set Vernier caliper 10 ton Steel shots (SB-1417)
(300)
1 set Vernier height 2pcs Grinding wheel
gage (1000mm) 50x50x300
5pcs Wheel grinder
180x20x6 dia
1 set Vernier height 10 pcs Mounted wheel
gage (500mm) 6x25x40
1 pc Divider (300mm) 3 cans Color check
2 pcs Trammel point 1 Hexagonal bar 25x3
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length meters long
1 pc Divider (200mm) 1 Steel wire 5mm dia x
length 3 meters long
1 pc Straight edge 2 cans Layout-blue
(510mm)
4 pcs Chisel 1 ½” wide 24 sets Cotton gloves
4 pcs Chisel 1” wide 24 sets Maong gloves
4 pcs Chisel 1/2 “ wide
4 pcs Chisel ¼” wide
1 set Tong
3.5 TRAINING FACILITIES
FOUNDRY METAL/CASTING NC II
Based on a class size of 12 students/trainees
SPACE SIZE IN METERS AREA IN SQ. TOTAL AREA IN SQ.
REQUIREMENT METERS METERS
Building (permanent) 26.00 x 28.00 728.00 728.00
Trainee Working Space 3.50 x 3.50 per 10.25 per 123
student / trainee student
Lecture room 9.00 x 10.00 90.00 90.00
Learning resource 5.00 x 8.00 40.00 40.00
center
Facilities / Equipment / - - 291.75
Circulation area
3.7 TRAINER’S QUALIFICATIONS FOR AUTOMOTIVE
MANUFACTURING SUB SECTOR
FOUNDRY MELTING/CASTING NC II
TRAINER QUALIFICATION (TQ II)
Must be a holder of Foundry Melting/Casting NC II
Must have undergone training on Training Methodology II (TM II)
Must be computer literate
Must be physically and mentally fit
*Must have at least 2 years job/industry experience
Must be a civil service eligible (for government position or appropriate
professional license issued by the Professional Regulatory
Commission)
* Optional. Only when required by the hiring institution.
Reference: TESDA Board Resolution No. 2004 03
3.7 INSTITUTIONAL ASSESSMENT
Institutional assessment is undertaken by trainees to determine their achievement
of units of competency. A certificate of achievement is issued for each unit of
competency.
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SECTION 4 NATIONAL ASSESSMENT AND CERTIFICATION ARRANGEMENTS
4.1.To attain the National Qualification of FOUNDRY MELTING/CASTING NC II, the
candidate must demonstrate competence in all the units listed in Section 1. Successful
candidates shall be awarded a National Certificate signed by the TESDA Director
General.
4.2 The qualification of Foundry-Melting/Casting NC II may be attained through.
4.2.1 Accumulation of Certificates of Competency (COCs) in all the following
areas:
Perform Melting/Casting Using Non-electric Melting Furnace
Operate Melting Furnaces (Non Electric)
Fettle and Trim Metal Castings
Perform Refractory Installation and Repair
Use and Maintain Measuring Instrument
Perform Melting/Casting Using Cupola Melting Furnace
Operate Cupola Melting Furnaces
Fettle and Trim Metal Castings
Perform Refractory Installation and Repair
Use and Maintain Measuring Instrument
Perform Melting/Casting Using Electric Induction Melting Furnace
Operate Electric Induction Melting Furnaces
Fettle and Trim Metal Castings
Perform Refractory Installation and Repair
Use and Maintain Measuring Instrument
4.3 Assessment shall focus on the core units of competency. The basic and common
units shall be integrated or assessed concurrently with the core units.
4.4 The following are qualified to apply for assessment and certification:
1.1.1 Graduates of formal, non-formal and informal including
enterprise-based training programs.
1.1.2 Experienced workers (wage employed or self-employed)
4.5 The guidelines on assessment and certification are discussed in detail in the
Procedures Manual on Assessment and Certification and Guidelines on the
Implementation of the Philippine TVET Qualification and Certification System
(PTQCS).
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
COMPETENCY MAP- AUTOMOTIVE SECTOR ANNEX A
MANUFACTURING SUB-SECTOR
FOUNDRY-MELTING/CASTING NC II
CORE COMPETENCIES
-
Develop and Develop and Develop and Develop and Perform general Use and maintain
manufacture wood manufacture polymer manufacture assembled manufacture production woodworking machine measuring instrument
pattern pattern plated pattern pattern operations
Prepare & mix sand for Produce molds by hand Produce cores by hand Operate molding Operate core-making Pour molten metal to Use and maintain
metal molding machine machine molds measuring instrument
Operate melting Operate cupola melting Operate electric Fettle & trim metal Perform refractory Use & maintain
furnaces (non-electric) furnace induction melting castings/forgings installation & repair measuring instrument
furnace
COMPETENCIES
COMMON
Read & Interpret Perform Mensuration Read, Interpret and Perform Shop
Engineering Drawings and Calculation Apply Specifications Maintenance
and Manuals
Receive and Practice basic Develop and Solve workplace
Work with Other Demonstrate Lead in workplace Use relevant
COMPETENCIES
respond workplace housekeeping practice negotiation problems related
work values procedures communication skills technologies
communication to work activities
Apply problem
BASIC
Participate in Practice career Practice occupational Use mathematical
workplace Work in team concepts and Develop team solving techniques
professionalism health and safety Lead small Team
environment procedures and individual in the workplace
communication techniques
Plan and Utilize specialist
organize work communication skills
Legend:
FOUNDRY-MELTING/CASTING NC II
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
DEFINITION OF TERMS (FOUNDRY)
An alloy is a homogeneous blend of two or more elements
1. Alloy
at least one of which is a metal, and where the resulting
material as metallic properties.
2. CarbonDioxide Carbon Dioxide Process consist of mixing a clean dry
Process silica sand with a silicate binder, compacting the mixture to
shape and hardening it by passing carbon dioxide gas.
3. Casting Casting is the term used to describe both the process and
the product when molten metal is poured and solidified in a
mold.
4. Chemical Analysis
Analytical chemistry is the science that seeks ever
improved means of measuring the chemical composition of
natural and artificial materials.
5. Cope In a two-part mold, the cope is the name given to the top
half of the pattern, flask, mold, or core.
The core is a sand shape that is inserted into the mold to
6. Core
produce the internal features of a casting, such as, holes or
passages for water-cooling.
7. Core Box A core box is the mold or die used to produce casting
cores.
8. Core Print The core print is the region added to the pattern, core, or
mold that is used to locate and support the core within the
mold.
9. Draft Draft is the taper on a pattern or casting that permits it to be
withdrawn from the mold.
10. Drag The drag is the bottom part of the two-part mold.
Dross is a mass of solid impurities floating on a molten
11. Dross
metal bath. It appears usually on the melting of low melting
point metals or alloys such as aluminum, copper,
magnesium or each alloys.
12. Fettle / Finishing The process of cleaning the casting, removal of excess
metal, grinding and inspection operation which may be
required for some casting process.
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
13. Flask The flask is the box that contains the molding aggregate.
A Foundry is a factory which produces metal castings from
14. Foundry
either ferrous or non-ferrous alloys.
Furnaces are refractory lined vessels that contain the
15. Furnace
material to be melted and provide the energy to melt it.
16. Gate Gate is controlled entrances to the mold cavity.
17. Gating System Gating system is the network of channels used to deliver
the molten metal to the mold cavity.
The term Green Sand refers to that molded sand mixture
18. Green Sand
which is allowed to remain moist and is used in casting
ferrous and non-ferrous metals.
The process includes melting the charge, refining the melt,
19. Melting
adjusting the melt chemistry and tapping into a transport
vessel. Refining is done to remove deleterious gasses and
elements from the molten metal. Material is added during
the melting process to bring the final chemistry within a
specific range specified by industry and/or internal
standards. During the tap, final chemistry adjustments are
made.
Is the process of making the mold cavity with a necessary
20. Molding
allowances such as shrinkage, machining, taper, and
surface finish. Usually it is done with green sand as the
molding medium.
21. Mold Cavity
The mold cavity is the shaped hole into which the molten
metal is poured and solidified to produce the desired
casting.
Parting Line or Parting Surface is the interface that
22. Parting Line
separates the cope and drag halves of a mold, flask, or
pattern. The same part can also be found in some core
making processes.
The pattern is the approximate copy of the final casting.
23. Pattern
The molding material (sand for sand molds) is then packed
around the pattern and the pattern is removed to produce
the mold cavity.
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
Dimensions added to the pattern to compensate for the solid
24. Pattern Shrinkage
shrinkage or contraction occurs in the solidified casting as it
Allowance
cools to room / ambient temperature.
A Pouring Cup or Pouring Basin is the portion of the gating
25. Pouring Cup
system that initially receives the molten metal from the
pouring vessel and controls its delivery to rest of the mold.
26. Refractories Refers to materials that are used to make crucibles, linings
for furnaces, kilns, ovens and incinerators. A practical
requirement is the ability of the material to withstand
temperatures above 1100oC without softening.
27. Riser
A riser is an extra void created in the mold that will also fill
with molten metal. It provides a reservoir of molten metal
that flow into the mold cavity to compensate for any
shrinkage during solidification.
Runners are the horizontal part of the gating system that is
28. Runners
connected to the gate.
29. Slag Are by-product of melting metals. They are composed of
metal oxides and sulfides. The assist in melt temperature
control and minimize oxidation of the liquid metal before
casting.
From the pouring cup, the molten metal travels down the
30. Sprue
sprue the vertical part of the gating system that connects
with the runners.
Vents are additional channels providing an escape for the
31. Vents
gasses that are generated within the mold.
Indicates the chilling tendencies of cast iron melt which is
32. Wedge Chill Test
related to melting conditions, chemical composition and
casting section thickness.
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TR FOUNDRY MELTING/ CASTING NC II Promulgated
ACKNOWLEDGEMENT
The Technical Education and Skills Development Authority (TESDA) wishes to
extend thanks and appreciation to the many representatives of business, industry,
academe and government agencies who rendered their time and expertise to the
development and validation of this Training Regulation.
THE TECHNICAL AND INDUSTRY EXPERT PANEL
FOUNDRY-MELTING/CASTING
Antonio A. Gimenez Cesar R. Leal Elmo N. Serbito
Philippine Automotive Philippine Automotive PAFI (Samahan ng mga
Federation, Inc. (PAFI) Federation, Inc. (PAFI) Manggagawang Supercast)
Carina J. Bondad
(Administrative Staff)
The PARTICIPANTS in the National Validation of this Training Regulation
(Supercast Foundry & Philippine Aluminum Wheels Toyota Auto Parts Phils. Inc.
Machinery Corp. Inc. (PAWI)
SFMC)
Philippine Resin Sand (PRS) ASPEC Corp.
Philippine Phospate
(PHILPHOS)
Members of the TESDA Board
The MANAGEMENT and STAFF of the TESDA Secretariat
TESDA EXCOM
Qualification and Standards Office
Florante P. Inoturan
Agnes P. Panem
Abel B. Elpedes
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